Graft polymers of polymerizable monomers and olefin polymers

ABSTRACT

Graft polymers are prepared by reacting an ethylenically unsaturated polymerizable monomer with a polymer of an olefin of 2 to about 8 carbon atoms in a process wherein the olefin polymer is substantially insoluble in the monomer but is capable of absorbing the monomer. In a preferred aspect, a vinyl halide polyolefin graft polymer is produced by reacting a solid polyolefin particle with a vinyl halide monomer in which the polyolefin is substantially insoluble, but is capable of absorbing the monomer. The solid particles can be contacted with the monomer in one step or in stages. When the stage-wise reaction is contined until the proportion of polyolefin in the polymer product is about 2 to about 20 weight percent, the resulting product can be formed to a transparent or translucent article. When a small proportion of solid polyolefin is employed in the polymerization process, both a graft polymer and a polymer of the unsaturated monomer are simultaneously produced in the same reactor and can be readily mechanically separated into the individual products.

BACKGROUND OF THE INVENTION

Polymers with excellent impact strength at ambient and very low temperatures are prepared by the polymerization in bulk liquid phase of a vinyl halide monomer and an olefin trunk polymer of hydrocarbon olefin moromers. The preparation of such polymers is disclosed in detail in U.S. Pat. Nos. 4,071,582; 4,163,033 and 4,169,870, to Takahashi, the disclosures of which are incorporated herein by reference.

The process described in the above-mentioned patents is primarily used at lower proportions of the polyolefin component, up to about 20 weight percent, and preferably up to about 10 weight percent. In the polymerization process, the reaction commences with the polyolefin component in solution or partial solution or dispersed in the vinyl monomer. As the reaction proceeds, the reaction mixture thickens to a latex-like consistency. As the conversion progresses, the reaction mixture enters the "paste stage" where it has a dough like consistency. Near the end of the reaction, the polymer mass in the reactor breaks up into discrete particles, which are recovered as the final product. In this process, when the polyolefin component is employed at higher proportions, and when the reaction proceeds to the higher conversions, the reaction product in the thick paste stage does not readily break down into particles. Accordingly, the process is not ordinarily used at proportions higher than about 20 weight percent of the polyolefin component.

The preparation of graft copolymers of unsaturated monomers and polyolefins is also disclosed in U.S. Pat. Nos. 3,489,821 and 3,489,822 to Witt et al. While these patents disclose the reaction of higher proportions of polyolefin, there is no enabling disclosure of the reaction being carried out in the bulk liquid phase. Thus, the patentees do not disclose the above described difficulty with respect to breakdown of the reaction mass from a dough-like consistency to discrete particles.

U.S. Pat. No. 3,408,424 to Barkhuff discloses the reaction of vinyl chloride with polyolefins at higher proportions, but the enabling disclosure of this patent is limited to the suspension process and there is no teaching with respect to the bulk liquid phase process. Therefore, the patentees do not disclose encountering the above-described problem with breakdown of a dough-like mass into discrete particles. Barkhuff at col. 5, line 71, teaches that grafting can occur to particles of polyolefin if finely suspended even if not fully dissolved, but he further points out that large rubbery lumps will be evident in the product if dispersing conditions are such as to give more than a small amount of polyolefin in this form.

More recently, in U.S. Pat. No. 3,978,162 to Nakanishi, the patentees were still attempting to react polyolefins at higher proportions in a suspension polymerization process much like in the just-described Barkhuff patent.

Severini et al. in U.S. Pat. No. 4,001,349 teach grafting styrene onto an ethylene, propylene, diene modified polymer (EPDM) in a process carried out in aqueous phase for at least part of the reaction. However, the patentees disclose dissolving the EPDM in the styrene monomer and reacting at higher temperatures at the beginning of the process. Likewise, Founier et al U.S. Pat. No. 4,166,081 and Hardt et al U.S. Pat. No. 4,276,391 and 4,054,613 teach preparation of polyolefin graft copolymers in solution at higher temperatures and then recovering the products from the solvent.

Lee in U.S. Pat. No. 4,098,734 teaches making graft polymer by dissolving a polybutadiene in monomers then carrying out a reaction in the usual way, eg, suspension, emulsion, bulk or combinations. He teaches that some polyebutadiene crosslinks can be used but points out that this may interfere with the required dissolving of the polybutadiene.

Beati et al at J. Applied Polymer Science, Vol. 26, 2185-2195 (1981) disclose reacting methyl methacrylate to an EPR or EPDM rubber in a process in which the EPDM is dissolved. Thereafter the mixture is suspended, the solvent is removed and the monomer is added to form the polymer.

Rademacher in U.S. Pat. No. 3,347,956 teaches a process to convert low density polyethylene into a very fine dispersion in vinyl chloride by heating to a high temperature under agitation and then cooling to form a dispersion of polyethylene in vinyl chloride where the particles have sizes in the 10-200 micron range (col. 4, line 73), more preferably 10-50 microns, and have large surface area. It is not clear whether a uniform graft polymer is made, or whether only a surface reaction occurs. But the patent clearly does not teach that grafting can occur within a large particle, as in the present invention.

Fisher et al. [J. Pol. Sci. Pol. Sym. 66, 443 (1979)] recognize the possibility of reacting ethylenically unsaturated monomers having polar groups such as ester, nitrile, amino, phenyl, ether, and the like, with the surface of polyolefins such as polyethylene, polypropylene and EPDMs in the forms of beads, films, fibres and tubing using monomer, and optionally a swelling agent, with high energy irradiation to surface polymerize or graft to the substrate. Other references to surface reaction (Japan 73/23,357) and a swollen polymer matrix [(Dokl Arad Nauk SSR 229 394 (1976)] have also recognized the possibility of polymerizing on or near the surface of particles or objects. However, they do not disclose or suggest the possibility of absorbing initiator and monomer throughout the particle and polymerizing throughout said particle to make a homogeneous product.

Thus, the prior art teaches making graft copolymers at high proportions of polyolefin but requires that the polyolefin be dissolved in a monomer and the mixture then either be suspended, emulsified or that a solution process take place at a high temperature to give the product. Other art teaches reaction on the surface of particles. The idea of absorption of monomer and initiator into particles which are not soluble in monomer followed by reaction of the monomer in the particles to give polymer and graft copolymer, which is the subject of this invention, has not been disclosed previously.

SUMMARY OF THE INVENTION

The process of the present invention enables the reaction of higher proporations of olefin polymers with ethylenically unsaturated polymerizable monomers to produce highly desirable graft polymers in particulate form. The process can be carried out without the need for a solvent or a carrier medium.

In accordance with one aspect of the invention, an ethylenically unsaturated polymerizable monomer is reacted with the polymer of an olefin of 2 to about 8 carbon atoms in a process wherein the olefin polymer is substantially insoluble in the monomer but is capable of absorbing the monomer. The process is truly remarkable in that solid particles of the olefin polymer are contacted with the monomer in liquid phase, the monomer is absorbed into the polymer particles and the polymerization occurs within the solid particles which are transformed into particles of reaction product.

In another aspect of the invention, a vinyl halide polyolefin graft polymer is produced by reacting a solid polyolefin particle comprising a polymer of an olefin of 2 to about 8 carbon atoms, preferably a polyolefin of an aliphatic hydrocarbon olefin of 2 to about 8 carbon atoms with a vinyl halide monomer either alone or in combination with up to 50 percent by weight based on the total weight of monomer of an ethylenically unsaturated compound copolymerizable therewith. In this process, the olefin polymer is substantially insoluble in the monomer, but is capable of absorbing the monomer.

The process of the invention is particularly useful for reacting polyolefins in a proportion of about 20 to about 80 weight percent based on the weight of the reactive monomer, although higher and lower proportions can be used. The preferred proportion is about 30 to about 50 weight percent of polyolefin based on the weight of the reactive monomer.

The products of the invention are advantageously prepared in a mass polymerization, but can also be prepared in the presence of an inert diluent, such as water.

In still another aspect of the invention, the solid particles of polyolefin are contacted with liquid monomer in stages, rather than contacting all of the solid polyolefin with all of the liquid monomer in one step.

It has been surprisingly found that when the stagewise reaction of liquid monomer for the solid polyolefin is continued until the proportion of the polyolefin in said polymer is about 2 to about 20 weight percent, preferably about 5 to about 10 weight percent based on the weight of the monomer, the resulting product can be molded to form transparent or translucent molded articles.

In still another aspect of the invention, a small proportion of solid polyolefin, in the range of about 0.1 to about 5 weight percent based on the weight of monomer is employed in the polymerization process so that both the graft polymer and a polymer of the ethylenically unsaturated monomer are produced simultaneously in the same reactor. The solid polyolefin particles are transformed into graft polymer. The polymer of the ethylenically unsaturated monomer forms as a finely divided powder which can be readily separated from the particles of the graft polymer to provide two distinct products from one reaction vessel.

The processes of the invention have many advantages over the prior art:

(a) By the use of pre-formed polyolefin particles or pellets, in solid form, no grinding and/or dissolving of the polyolefin reactant is required.

(b) The polyolefin particles can be reused in a subsequent reaction in the event that for some reason the reaction does not proceed the first time. This feature can also be used to modify the proportions of polyolefin and reacted monomer after an initial reaction.

(c) Graft polymer and a homopolymer of an ethylenically unsaturated compound can be made concurrently in the same process in a form that is easily separated.

(d) The size of the initial polyolefin particles establishes the particle size of the final product. There are no large agglomerated particles and the production of undersized fine particles can be substantially eliminated.

(e) The process may be conducted in the presence of inert diluents if desired.

(f) The process can be carried out in a single reaction vessel.

The products of the invention have many advantages including:

(a) High proportions of polyolefin can be reacted into the graft polymer product.

(b) Useful blends of the graft polymer with other polymers can be made.

(c) The vinyl halide graft polymer of the invention can be blended with a polyvinyl chloride prepared by any desired process to give the desired final properties.

(d) A transparent or translucent vinyl halide polyolefin graft polymer is commercially feasible for the first time.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Monomer Component

In the broad aspect of the invention, the novel graft polymers of the invention is prepared from one or more ethylenically unsaturated compounds that is polymerizable in the presence of a free-radical initiator. Suitable ethylenically unsaturated compounds which can be used are illustrated by the following compounds. Monoolefinic hydrocarbons, i.e.. monomers containing only carbon and hydrogen, including such materials as ethylene, propylene, 3-methylbutene-1, 4-methylpentene-1, pentene-1, 3,3-dimethylbutene-1, 4,4-dimethylbutene-1, octene-1, decene-1, styrene and its nuclear, alpha-alkyl or aryl substituted derivatives, e.g., o-, m- or p-methyl, ethyl, propyl or butyl styrene, alpha-methyl, ethyl, propyl or butyl styrene; phenyl styrene, and halogenated styrenes such as alphachlorostyrene; monoolefinically unsaturated esters including vinyl esters, e.g., vinyl acetate, vinyl propionate, vinyl butyrate, vinyl stearate, vinyl benzoate, vinyl-p-chlorobenzoates, alkyl methacrylates, e.g., methyl, ethyl, propyl, butyl, octyl and lauryl methacrylate; alkyl crotonates, e.g., octyl; alkyl acrylates, e.g., methyl, ethyl, propyl, butyl, 2-ethylhexyl, stearyl, hydroxyethyl and tertiary butylamino acrylates, isopropenyl esters, e.g., isopropenyl acetate, isopropenyl propionate, isopropenyl butyrate and isopropenyl isobutyrate; isopropenyl halides, e.g., isopropenyl chloride; vinyl esters of halogenated acids, e.g., vinyl alpha-chloroacetate, vinyl alpha-chloropropionate and vinyl alpha-bromopropionate; allyl and methallyl compounds, e.g., allyl chloride, allyl alcohol, allyl cyanide, allyl chlorocarbonate, allyl nitrate, allyl formate and allyl acetate and the corresponding methallyl compounds; esters of alkenyl alcohols e.g., beta-ethyl allyl alcohol and beta-propyl allyl alcohol; halo-alkyl acrylates, e.g., methyl alpha-chloroacrylate, ethyl alpha-chloroacrylate, methyl alphabromoacrylate, ethyl alpha-bromoacrylate, methyl alpha-fluoroacrylate, ethyl alpha-fluoroacrylate, methyl alpha-iodoacrylate and ethyl alpha-iodoacrylate; alkyl alpha-cyanoacrylates, e.g., methyl alpha-cyanoacrylate and ethyl alpha-cyanoacrylate and maleates, e.g., monomethyl maleate, monoethyl maleate, dimethyl maleate, diethyl maleate; and fumarates, e.g., monomethyl fumarate, monoethyl fumarate, dimethyl fumarate, diethyl fumarate; and diethyl glutaconate; monoolefinically unsaturated organic nitriles including, for example, fumaronitrile, acrylonitrile, methacrylonitrile, ethacrylonitrile, 1,1-dicyanopropene-1, 3-octenonitrile, crotononitrile and oleonitrile; monoolefinically unsaturated carboxylic acids including, for example, acrylic acid, methacrylic acid, crotonic acid, 3-butenoic acid, cinnamic acid, maleic, fumaric and itaconic acids, maleic anhydride and the like. Amides of these acids, such as acrylamide, are also useful. Vinyl alkyl ethers and vinyl ethers, e.g., vinyl methyl ether, vinyl ethyl ether, vinyl propyl ether, vinyl n-butyl ether, vinyl isobutyl ether, vinyl 2-ethylhexyl ether, vinyl-2-chloroethyl ether, vinyl propyl ether, vinyl n-butyl ether, vinyl isobutyl ether, vinyl 2-ethylhexyl ether, vinyl 2-chloroethyl ether, vinyl cetyl ether and the like; and vinyl sulfides, e.g., vinyl beta-chloroethyl sulfide, vinyl beta-ethoxyethyl sulfide and the like can also be included as can diolefinically unsaturated hydrocarbons containing two olefinic groups in conjugated relation and the halogen derivatives thereof, e.g., butadiene-1,3; 2-methylbutadiene-1,3, 2,3-di-methylbutadiene-1,3; 2-methylbutadiene-1,3; 2,3-dimethylbutadiene-1,3; 2-chlorobutadiene-1,3; 2,3-dichloro-butadiene-1,3; and 2-bromo-butadiene-1,3 and the like. Mixtures of the foregoing compounds can also be employed.

Particularly useful monomer compositions include styrene, methyl methacrylate, methyl acrylate, vinyl acetate, mixtures of styrene and acrylonitrile, and mixtures of styrene and various maleates.

In one aspect of the invention, the preferred monomer composition is comprised totally of a vinyl halide monomer. Suitable vinyl halide monomers useful in the invention are the halo-substituted ethylenically unsaturated compounds which are capable of entering into an addition polymerization reaction, for example vinyl monohalides such as vinyl fluoride, vinyl chloride, vinyl bromide, and vinyl iodide, as well as vinyl dihalides such as vinylidene fluoride, vinylidene chloride, vinylidene bromide, and vinylidene iodide and the like. Higher halo-substituted compounds can also be used. Vinyl chloride is preferred.

While it is preferred that the monomer composition be comprised totally of vinyl halide monomer as described above, the present invention is also intended to include copolymers formed by the free-radical addition polymerization of a monomer composition containing a predominant amount, e.g., at least 50 percent of vinyl halide with the remainder being another ethylenically unsaturated monomer composition copolymerizable therewith. Preferably, the other ethylenically unsaturated monomer is used in amounts of 20 percent or less by weight and more preferably in amounts of 10 percent or less by weight of the total monomer used in preparing the polymer.

Specific monomer compositions for forming copolymers can be illustrated by vinyl chloride and/or vinylidene chloride and vinyl acetate, vinyl chloride and/or vinylidene chloride and maleic or fumaric acid esters, vinyl chloride and/or vinylidene chloride and acrylate or methacrylate ester, vinyl chloride and/or vinylidene chloride and vinyl alkyl ether. These are given as illustrative of the numerous combinations of monomers possible for the formation of copolymers. The present invention includes all such combinations.

Polyolefin Component

The polyolefin component of the invention is characterized by being substantially insoluble in the reactive monomer component, and it remains insoluble during the polymerization reaction. The polyolefin is also capable of absorbing the reactive monomer component. For most polyolefin/monomer combinations, when the proportion of polyolefin in the reaction mixture is at least about 20 weight percent of the reactive components, essentially all of the monomer component is absorbed into the particles of polyolefin component where the reaction occurs.

Generally, the polyolefin is capable of absorbing monomer to the extent of at least about 10 weight percent of the weight of polyolefin, usually at least about 25 weight percent and more usually at least about 100 weight percent of the weight of polyolefin. Generally, the polyolefin can absorb monomer up to 10 times the weight of polyolefin, more usually up to about 400 weight percent and still more usually up to 300 weight percent of the weight of polyolefin. The polyolefin may swell in the presence of the monomer. But the polyolefin remains as a free flowing particle that does not agglomerate or fuse.

The preferred polyolefins are prepared from unsubstituted, aliphatic hydrocarbon monoolefins, including straight chain and branched chain compounds such as ethylene, propylene and butene-1, isobutene, pentene, hexene, heptene, octene, isobutene, 3-methylbutene-1, 4-methylpentene-1,4-methylhexene-1, and 5-methylhexene-1.

The polyolefin also preferably contains an unsubstituted, aliphatic hydrocarbon polyene, such as diene or triene, as a monomer unit. Such unsubstituted compounds can be straight chain, branched chain or cyclic compounds. Generally polyenes of from 5 to 18 carbon atoms are employed.

Suitable comonomers for preparing the polyolefins are those utilized to prepare homopolymers as listed above such as propene or butene-1 with ethylene or isobutylene with isoprene and the like. Suitable termonomers are those utilized to prepare homopolymers and copolymers as disclosed above such as propene, ethylene and the like containing up to 15 percent, preferably up to about 10 percent by weight of polyene, for example, a diene such as dicyclopentadiene, 1,3-butadiene, 1,5-cyclooctadiene, 2-ethylidenenorbornene-5, 1,4hexadiene, 1,4-heptadiene, bicyclo(2.2.1)-hepta-2,5-diene and other conjugated and especially noncojugated dienes with linear or cyclic chains.

Trienes such as isopropylidene cyclopentadiene and the Diels-Alder mono- and di- adducts thereof with cyclopentadiene can be used in place of the diene.

Unsubstituted, aliphatic diolefins can also be used for preparing useful polyolefins such as butadiene, isoprene, octadiene, and the like. Especially useful are the various forms of polybutadiene, such as made in emulsion, suspension or solution processes. and random, block, and star block polymers with monomers such as styrene.

Various other polyolefins that contain other than hydrogen and carbon can also be employed as long as they meet the criteria of being insoluble in the reactive monomer and capable of absorbing that monomer. Such polyolefins are generally polymers of substituted, aliphatic hydrocarbon olefins of 2 to about 8 carbon atoms, and are more particularly polymers of an unsubstituted, aliphatic hydrocarbon olefin of 2 to about 8 carbon atoms and a substituted, aliphatic hydrocarbon olefin of 2 to about 8 carbon atoms. Suitable substituted hydrocarbon olefins include vinyl acetate, vinyl benzoate, and other vinyl esters with organic acids and haloacids, isopropenyl acetate and other esters, methyl methacrylate and other alkyl methacrylates, methyl acrylate, ethyl acrylate and other alkyl acrylates, and olefins. Included in such additional polyolefins are olefin-vinyl acetate copolymers, such as ethylene-vinyl acetate copolymers; olefin-acrylate copolymers, such as ethylene-acrylate copolymers; polychlorobutadiene, and the like.

Suitable polyolefin components include the above described homopolymers, copolymers or terpolymers, but can also include blends of two or more polyolefins that may not meet the criteria in themselves, but the blended composition is insoluble in the reactive monomer but capable of absorbing the reactive monomer. Thus, certain ethylene propylene diene modified polymers (EPDM) are soluble in vinyl chloride monomer, and hence are not suitable when used alone in the process of the invention. High density polyethylene (HDPE) is insoluble in vinyl chloride monomer, but does not absorb that monomer, and hence is not suitable when used alone in the process of the invention. However, it is found that mixtures of ethylene propylene diene modified polymers and high density polyethylene when melt blended are highly desirable in the process of the invention. The higher the ethylene content of the EPDM, the lower the amount of HDPE required. Particularly suitable are HDPE's having a melt index of 0.1 to 50, blended with a polyolefin, for example, EPDM at a ratio of from 1 to 20 to 20 to 1.

Low density polyethylene is found to be both insoluble in vinyl chloride monomer and capable of absorbing that monomer, and is useful in the process of the invention. The very low density polyethylene waxes, on the other hand, are soluble in vinyl chloride monomer and hence are not suitable when used alone in the process of the invention. Other useful blends of polyolefins include blends of polybutadiene and high density polyethylene. Very high molecular weight polymers, e.g. polybutadiene of weight average molecular weight of over 1,000,000, or ethylene propylene copolymer of weight average molecular weight over 300,000, function in this manner without blending in reactions where their lower homologs may need to be blended to meet the nonsolubility requirement. It is to be understood that a given blend or polymer may be substantially insoluble in certain monomers but is soluble or partially soluble in other monomers. Where partial solubility is involved, suitability of the polymer or blend and monomer combination for the purposes of the present invention depends on whether the graft polymer produced is in substantial particulate form.

The polyolefin used in the invention is in particulate form. The particles may be pellets, such as formed by extrusion through an orifice and cutting into pellets by a dicer. The particles can also be formed as pellets in a pellet forming device. The polyolefin is generally in the form of particles measuring in the range of about 1 to about 5 millimeters, preferably about 1 to about 3 millimeters. Other particle sizes can be used. The particles can be of various shapes, such as beads and cylinders, pill shaped, as well as in irregular shapes resulting from grinding.

Reaction Conditions

The products of the invention are preferably prepared in a mass polymerization process wherein solid discrete particles or pellets of solid polyolefin are mixed with a monomer component in the liquid state and a free-radical initiator compound at ambient temperatures. All or part of the mixture of monomer and initiator compound is absorbed into the solid polyolefin particles.

It is preferred to put all the monomer into the reactor with the polyolefin at the beginning of the reaction. However, the monomer can be added incrementally during the reaction. As indicated hereinbefore, the monomer can be reacted with the polyolefin in steps to achieve the desired product. Generally only sufficient monomer is introduced at one time to the polyolefin to avoid the formation of powdered polymer, except, of course, in the aspect of the invention where co-manufacture of particles of graft polymer and powdered homopolymer or copolymer is desired. When operating in the stepwise embodiment, the amount of monomer added in the second and subsequent steps does not usually exceed the ratio of monomer to polyolefin established in the first step of the sequence.

The reaction mixture is heated to a temperature in the range of about 30 to about 90 degrees Celsius, preferably in the range of about 40 to abuut 75 degrees Celsius, more preferably in the range of about 60 to about 70 degrees Celsius, and the reaction is allowed to proceed to the desired conversion of monomer, generally in the range of about 30 to 90 percent conversion, preferably about 50 to 80 percent conversion, and more preferably about 60 to 75 percent conversion. Thereafter, the unreacted monomer component is removed from the reaction mixture by suitable degassing techniques such as by direct degassing, by drawing a vacuum on the reaction product, by washing with water or a solvent or by steam distillation. The solid reaction product is withdrawn from the reaction vessel as the product of the process.

Initiators

Suitable initiator compounds for use in the process of the invention include organic or inorganic peroxides, persulfates, ozonides, hydroperoxides, peracids and percarbonates, azo compounds, diazonium salts, diazotates, peroxysulfonates, trialkyl borane-oxygen systems, and amine oxides. Suitable initiators are soluble in the organic phase, such as peroxides: benzoyl peroxide, capryl peroxide, lauroyl peroxide, 2,4-dichlorobenzoyl peroxide, diacetyl peroxide, and acetyl cyclohexylsulfonyl peroxide; azo compounds: azobisisobutyronitrile, azobis(alpha-methylgammacarboxybutyronitrile), azobis(alpha,gamma-dimethylvaleronitrile), 2,2'-azobis(2,4-dimethylvaleronitrile); peroxydicarbonates: diisopropyl peroxydicarbonate, di-sec-butyl peroxydicarbonate, and dicyclohexylperoxydicarbonate, azobisisobutyramidine hydrochloride, and peresters: t-butyl peroxypivalate and t-butyl peroxyneodecanoate. Peroxydicarbonates, peresters and peroxides are particularly useful in the present invention. The initiator is used in concentration ranging from about 0.01 to about one percent by weight, preferably about 0.1 to about 0.5 percent by weight, based on the total weight of the monomers. Amounts of initiator sufficient to initiate the reaction should be used. The best amount may vary depending on reaction temperature, nature of the polyolefin or allowed reaction time.

Diluents

Various diluents may be used in the process of the invention. Preferably, the diluents employed should be substantially non-reactive with the products of the invention and do not dissolve the products of the invention. The most common diluent is water, which may be used without any suspending or emulsifying agent. Essentially, when water is used as the diluent, the particles of solid polyolefin float in the water phase and during the reaction process are dispersed through the water phase by suitable agitation.

Other diluents include organic compounds such as saturated hydrocarbons having from about 3 to about 15 carbon atoms per molecule. Preferably, the diluent is a straight or branched chain, or cyclic saturated hydrocarbon having from 3 to 15 carbon atoms, and more preferably, from 4 to 8 carbon atoms. Alcohols of 1 to 15 carbon atoms can also be employed.

Illustrative examples of suitable diluents which can be employed in the present process include n-propane, n-butane, isobutane, isopentane, neopentane, 2-methylpentane, 3-methylpentane, 2,2,4-trimethylpentane, 2,2,3-trimethylpentane, n-tridecane and n-pentadecane. Mixtures of these and other hydrocarbon alkanes, as well as cycloalkanes, such as cyclohexane and methyl cyclopropane, can be used also. Useful alcohols include ethyl, isopropyl, butyl, isobutyl, octyl and dodecyl alcohols, ethylene glycol, propylene glycol, 1,3-dihydroxypropane, and the like.

The diluents can enter the polyolefin particle as in the case of hydrocarbons, or may stay out as in the case of water, or may do both.

When water is used as the diluent, the proportion may range from about 10 to about 1000 percent by weight based on the organic phase (polyolefin plus monomers), more preferably from about 100 to 400 percent by weight.

If an alcohol, hydrocarbon or other diluent is used, the proportion can be from about 0.1 to 100 percent by weight based on the polyolefin plus monomer, more preferably between 1 to 5 percent by weight.

Chain Transfer Agents

Chain transfer agents can be used in the process of the invention. One purpose of such chain transfer agents is to adjust the molecular weight of the polymerized monomer starting material. The polyolefin component itself is found to serve as a chain transfer agent by changing the molecular weight of the PVC produced in the case of vinyl chloride monomer. Other transfer agents that can be used include aldehydes, mercaptans such as mercaptoethanol, dodecylmercaptan; chloroolefins such as perchloroethylene, trichloroethylene, halomethanes such as bromoform, olefins, substituted isopropyl compounds, thiotin compounds, such as alkyltin mercaptoacetate esters and the like.

When a chain transfer agent is used,, the proportion is generally in the range of about 0.1 to about 10 percent by weight, preferably from about 0.5 to about 2 percent by weight.

Stabilizers

The products of the invention are preferably stabilized against the adverse effects of heat, light and other environmental factors by introducing suitable stabilizers at the end of the polymerization reaction, but prior to the venting or degassing step to remove unreacted monomer, as well as, in subsequent compounding of the product with other additives. Surprisingly, the stabilizer can also be introduced at the beginning of the reaction. All or a combination of these stabilization techniques can be employed.

The polymer product of the invention has the advantage that it can absorb monomers, solvents and other liquid additives. This feature can be relied on to facilitate stabilization of the product. Prior to the degassing step to remove monomer, which step often discolors the product because of heat, a stabilizer can be added to the polymer particles. The stabilizer compound is absorbed into the particle to protect the polymer during degassing. In practice, the stabilizer can be mixed with monomer compound and then introduced to the reactor and mixed with the polyolefin particles. Another suitable liquid, such as an alcohol, can also be added with the monomer to facilitate absorption of the stabilizer into the monomer. Heating also helps to drive the stabilizer into the pellets. The stabilizer, monomer and other liquid, are absorbed into the polyolefin particles. Thereafter the monomer and other liquid are removed, such as, by heating, application of vacuum, steam distillation, and the like, leaving the stabilizer in the particles to protect the polymer.

Suitable stabilizers include salts of polyvalent metals such as cadmium, manganese, cerium, strontium, calcium, tin, barium, magnesium and lead and alkanoic monocarboxylic acids of 6 to 20 carbon atoms. Typical salts include the stearates, laurates, caproates, undecylates of the foregoing metals. Also used are amine stabilizers such as diphenyl amine, thiourea, aryl thiourea and the like. Also known as useful stabilizers are the alkyl esters of organotinmercaptide substituted alkanoic acids. The alkyl group in the ester part of the molecule may be methyl, n-butyl, ethyl, hexyl, isooctyl or other group. The organo groups on the tin atom may include methyl, butyl or octyl, while examples of the base alkanoic acids are acetic or butyric. Esters of dibutyl tin bis (iso-octyl mercaptoacetic acid) are particularly effective in this regard. Also useful in this connection are di- and tri-alkyl tin derivatives of C₂ -C₁₈ alkanoic acids such as di-n-butyl tin diacetate and tri-n-octyl tin laurate. An especially good result is obtained using a mixture of the dioctyl tin stabilizers, namely a mixture of di-n-octyl tin mercaptide of mercapto acetic acid, iso-octyl ester and tri-n-octyl tin laurate.

The dialkyltin maleates are useful stabilizers. They are more effective when dissolved or mixed with an alcohol, such as ethanol or other alcohol having up to 18 carbon atoms. The dialkytin maleates with alcohol can be advantageously added at the start of the reaction without adverse effects on the reaction apd yet providing the desired stabilization effects on the polymer product.

Other suitable stabilizers include various phosphite esters. These can include alkylphenyl phosphites such as nonylphenyl phosphite or 4,4-isopropylidene-diphenol, alkyl phosphite esters where the alkyl group contains 12-15 carbon atoms.

The stabilizers are employed in a proportion of about 0.01 to about 1 percent by weight, preferably about 0.05 to about 0.5 percent by weight, more preferably, about 0.1 to about 0.5 percent by weight, based on the weight of polymer. The most preferred range for the dialkyltin maleate with alcohol is about 0.05 to about 0.12 weight percent.

Color Removal Reaction

If the product is not stabilized or if a poor stabilizer is used and the product pellets come out highly colored due to decomposition during the high temperature degassing step where the PVC portion of the product decomposes into colored polyene units, it is possible to reverse this reaction in a post treatment using a small amount of monomer or monomer mixtures and free radical initiator that will react with the polyene units. An inert fluid medium may assist in transporting the monomer into the particles. Monomers listed under monomer components may be used where methyl methacrylate and styrene are particularly effective in this regard. Initiators listed hereinabove may be used. Any liquid that will dissolve the monomer and initiator and which will be absorbed by the solid product may be employed in this process. Hydrocarbons are particularly useful in this regard. The reaction proceeds effectively at 65° C. although with proper choice of components may be carried out between 30° and 90° C.

Product Components

In the polymerization reactions of the invention, a portion of the polyolefin is grafted with a portion of the unsaturated monomer to form a grafted polymer component. The product contains polyolefin and may contain some homopolymer or copolymer component resulting from polymerization of some of the unsaturated monomer or monomers. The proportions of the various components vary depending on reaction conditions. Chart A shows a typical range of proportions of the various components of the products of this invention.

                                      CHART A                                      __________________________________________________________________________     Components of Graft Polymer Products of Invention                              Proportion                Ungrafted                                                                            Homopolymer or Copolymer                       Weight Percent            Polyolefin                                                                           of Unsaturated Monomer                         __________________________________________________________________________             Total Polymer                                                                          Graft Polymer                                                  General 100     15-25     5.25  0--80                                          Preferred                                                                              100     20-60     --                                                   Most Preferred                                                                         100     30-50     2-10                                                         Proportion of                                                                  Polyolefin                                                                             Grafted Polyolefin                                             General 20-80    5-60     5-25                                                 Preferred                                                                              25-60   10-50     --                                                   Most Preferred                                                                         30-50   20-40     2-10                                                         Proportion of                                                                  Monomer Grafted Monomer                                                General 20-80    5-40           0-80                                           Preferred                                                                              40-70   --                                                             Most Preferred                                                                         50-60   10-30                                                          __________________________________________________________________________

Uses of Products

The polymers of this invention can be formed into useful articles such as bottles, sheeting, wire and cable coatings, films, membranes, pipe, fittings, appliance housings, roofing membranes, and the like where such properties as impact (room temperature or lower) heat distortion, tensile or flexural strength, fire retardance, clarity, oil resistance, long term retention of properties, etc. may be obtained depending on the exact nature of the monomer and polymer. The polymers can be compounded with or processed with such things as fillers (mineral, inorganic or organic) plasticizers, process aids, stabilizers, lubricants, coloring agents, such as organic or inorganic pigments, and the like. The products may be further reacted with other monomers to make a thermosetting product or may be crosslinked, vulcanized or further reacted in other ways.

A more detailed description of suitable stabilizers, lubricants and processing aids for incorporation into the compositions of the invention is presented in U.S. Pat. No. 4,319,002, the disclosure of which is incorporated herein by reference.

Additional classes of additives known for use in polyvinyl halide resins which can be added optionally to the compositions of the invention in addition to the aforementioned stabilizers, lubricants and processing aids include pigments, dyes and fillers as described in L. R. Brecker, Plastics Engineering, March 1976, "Additives 76", pages 3-4, the disclosure of which is incorporated herein by reference.

In general, the amount of each type of the aforementioned optional additive employed in the present composition is about 0.01 to about 5 weight percent, preferably about 0.1 to about 3 weight percent, based on the total resin composition.

The graft polymers of the invention can be blended with polymers and copolymers, polymerized from the same unsaturated monomer or monomers used in preparing the graft polymers of the invention. Thus, graft polymers of a vinyl halide and a polyolefin can be blended with various preparations of a polyvinyl halide to provide a family of polymer products having utilities such as listed for the base graft polymer. An especially useful composition includes an EPDM-PVC graft polymer blended with PVC homopolymer which has been molded or extruded into useful objects having improved impact properties with good retention of these properties. Another useful composition includes the above-described blend which additionally includes chlorinated PVC to give an impact polymer with improved heat distortion temperature. Other useful blends include those obtained by grafting to EPDM, polybutadiene (PBD), ethylene vinyl acetate copolymer or styrene butadiene block copolymers, such monomers or mixtures of monomers as vinyl chloride, styrene with acrylonitrile, methyl methacrylate, styrene, acrylonitrile, styrene with butyl maleate, styrene with maleic anhydride, cyclohexylacrylate, styrene with methyl methacrylate, methyl acrylate, methyl acrylate with styrene and lauryl methacrylate, and blending such graft polymers with the respective polymers or copolymers of the listed monomers or comonomers.

The graft polymer of the invention can be blended with various other polymers to provide products with different properties than the base graft polymer. Such other polymers include glassy, crystalline polymers, rubbery polymers and mixtures thereof as exemplified by ABS polymers. Examples of such polymers include polyvinyl chloride, styrene-acrylonitrile copolymers (SAN), polymethylmethacrylate (PMMA), chlorinated polyvinyl chloride (CPVC), graft copolymers of acrylonitrile and styrene on polybutadiene or a blend of acrylonitrile butadiene copolymer with styrene acrylonitrile copolymer (ABS), polyolefins, such as polyethylene and polypropylene, polystyrenes, poly α-methylstyrene, ABS-polycarbonate alloys, acetal polymers, cellulosic polymers, fluoropolymers, ionomers, nylons, polyphenylene oxide polymers, polysulfones, polyether sulfones, polyallomer, poly(ethylene vinyl acetate), poly(ethylene ethyl acrylate), polymethyl pentene, polyphenylene sulfide, thermoplastic elastomers, alkyl resins, epoxy resins, silicone polymers, urethane polymers, and the like, and any two or more of the foregoing polymers. Particularly useful blends include those obtained by grafting to EPDM, polybutadiene, ethylene vinyl acetate copolymer or styrene butadiene block copolymers, such monomers or mixtures of monomers as vinyl chloride, methyl methacrylate, cyclohexyl acrylate and styrene with methyl methacrylate, and blending such graft polymers with polymers such as polyvinyl chloride, styrene-acrylonitrile copolymers, polystyrene and acetal polymers.

Blends of the graft polymers of the invention with the just described other polymers and with the previously described polymers and copolymers polymerized with the same monomer or monomers used in preparing the graft polymers, are also contemplated. Typical of these blends include the graft polymer, polyvinyl chloride and a third polymer such as polystyrenes, styrene acrylonitrile copolymers, ethylene, propylene polyene modified polymers, polyethylene, chlorinated polyvinyl chloride, and a graft copolymer of styrene and acrylonitrile on polybutadiene or a blend of acrylonitrile butadiene copolymer and styrene acrylonitrile copolymers (both forms of ABS polymers), and the like. In some of the foregoing blends, the graft polymers of the invention are useful for compatibilizing otherwise non-compatible polymers such as polyvinyl chloride and polyethylene. The graft polymer can have end groups or parts similar to one or the other of the two materials.

Especially useful blends of the products of the invention include (1) blends with polymers of acrylonitrile and styrene with polymers such as chlorinated polyethylene, acrylic rubber and ethylene propylene diene polymers, such as disclosed in copending application Ser. No. 541,399, filed on even date herewith; (2) blends with styrene maleic anhydride copolymers such as disclosed in copending application Ser. No. 541,398, filed on even date herewith; and (3) blends with condensation polymers such as polycarbonates and polyesters, such as disclosed in copending application Ser. No. 541,195, filed on even date herewith.

Proportions of the polyolefin graft polymer in binary blends with any other polymer can range typically from less than about 1 pecent to more than about 99 weight percent of graft polymer (with the balance being the other polymer component). It is preferred to provide blends which contain about 5 percent up to about 80 percent of the polyolefin graft polymer to achieve the desired enhanced properties. Preferred blends of this aspect of the invention contain about from about 10 percent to about 60 percent of the graft polymer component and from about 40 percent to about 90 percent of the other polymer component, said percentages being based on the weight of the blend of the graft polymer and the other polymer.

With respect to the aspect of the invention involving not only the graft polymer component and a second polymer component, but also an auxilliary polymer comprising a polymer or copolymer, the proportions of components are in the following ranges. The second polymer component is generally present in a proportion of about 20 percent to about 80 percent of the total polymer components, with the remainder being the polyolefin graft copolymer and the auxilliary polymer component. The latter two components are generally present in the proportion of about 10 parts polyolefin graft polymer to 90 parts auxilliary polymer to about 90 parts polyolefin graft polymer to 10 parts auxilliary polymer. The range is preferably from about 20 parts polyolefin graft polymer to 80 parts auxilliary polymer to 40 parts auxilliary polymer to about 30 parts polyolefin graft polymer to 60 parts auxilliary polymer. All parts and percentages are by weight.

THE EXAMPLES

The following examples are intended to illustrate but not limit the invention. Unless indicated otherwise in this specification and claims, parts, ratios and proportions are by weight, and temperatures are in degrees Celsius.

Example 1--Preparation of a Pelletized Polyolefin Graft Copolymer with Vinyl Chloride

Into a one liter glass autoclave equipped with a heating jacket and stirrer with helical elements, were charged 75 grams of a commercially pelletized blend of polyolefins containing approximately 85 weight percent of an EPDM elastomer having a molar ratio of ethylene to propylene of about 72 percent to 28 percent, and 3 double bonds of unsaturation as 1,4-hexadiene per 1,000 carbon to carbon bonds (db/1,000 C-C) of approximately 170,000 weight average molecular weight with about 15 weight percent high density polyethylene. The particle size of the pelletized blend was about 3 mm in diameter by 1.5 mm in thickness. The vessel was pressurized to 180 psig with nitrogen and the pressure was released. A solution of 0.5 ml of a 75% solution of the t-butyl peroxy neodecanoate in mineral spirits (free radical initiator) and about 305 grams vinyl chloride was added. About 5 grams of the vinyl chloride was vented from the reactor to purge volatile gasses to give a net charge of vinyl chloride of 300 grams. The mixture was heated with circulating water at 60° and was stirred at a rate of 100 rpm. Initially the mixture consisted of pellets floating on top of liquid monomer at 40 psig, and the total filled the reactor to the 500 ml mark. On heating and stirring, the liquid vinyl chloride phase gradually disappeared and the pellets became swollen. After 40 minutes of heating and stirring the liquid phase ceased to exist. The only liquid was that which refluxed from the unheated top of the reactor. The reactor now at IDB psig contained loose white swollen pellets to the 600 ml mark. The mass remained as swollen white pellets with traces of powder. The volume of the mixture gradually increased until a maximum of 800 ml was reached at 1.2 hour after start of heating. A maximum pressure of 165 psig was reached at 1.3 hour after start of heating. At this point, the temperature of the heating medium was dropped to 57° C. and held there for 20 minutes and then returned to 60° C. By this time (now 1.7 hour after start of heating), the pressure was 145 psig and the pellets were starting to "dry". There were traces of liquid still refluxing from the top of the reactor. After another 50 minutes, the pressure had fallen to 95 psig, the volume of loose stirring pellets decreased to 700 ml. and the reaction was terminated by venting unreacted monomer to a recovery system. The product contained 322 grams of material. Thirty grams of this was as agglomerated pellets in the lower corners of the reactor while the rest or 292 grams consisted of white free flowing pellets (91% of the total product) about 2-3 times the size of the starting pellet material. The polyolefin content of the final product was calculated by the following equation:

    (75 grams polyolefin/322 total product) 100=23% total polyolefin. Equation 1

The vinyl chloride conversion to polymer is given by equation ##EQU1##

The polyolefin-PVC product mixture was separated into its individual components taking advantage of the solvent-nonsolvent properties of the solvents listed in Table 1 for the individual components in the mixture.

                                      TABLE 1                                      __________________________________________________________________________               SOLVENT                                                                                 Branched Hydrocarbon                                                  Perchloroethylene                                                                       Mixture bp 100°                                                                            Dimethyl Formamide                       Fraction  (100° C.)                                                                        (Shaken @65° C., Determined @25°                                                    (Shaken 65° cooled to                                                   25° C.)                           __________________________________________________________________________     PVC Homopolymer                                                                          Trace Soluble                                                                           Insoluble          Soluble                                  EPDM in the                                                                              Soluble  Soluble            Insoluble                                initial Poly-                                                                  olefin Blend                                                                   HDPE in the                                                                              Soluble  Insoluble          Insoluble                                initial Poly-                                                                  olefin Blend                                                                   Polyolefin Graft                                                                         Small Amount                                                                            Insoluble          Insoluble                                Copolymer Soluble                                                              __________________________________________________________________________

A method to approximately determine such compositions consists of heating about 5 grams (accurately weighed) of pellets with 200 ml perchloroethylene in a steam bath overnight, decanting the solvent from the swollen floating pellets with a large syringe, then repeating with another portion of perchloroethylene and heating another 3-4 hr. at 100° C. and again decanting. The combined perchloroethylene extract is freed of solvent on a rotary evaporator. This predominantly polyolefin fraction is extracted with dimethylformamide to remove traces of PVC homopolymer, freed of residual dimethylformamide, then extracted with a hot branched hydrocarbon mixture with cooling to room temperature before decanting. Concentration of this hydrocarbon extract gives predominantly the unreacted EPDM part of the polyolefin. The insoluble fraction is a mixture of ungrafted high density polyethylene, with some polyolefin grafted with PVC. It is possible to estimate the amounts of the two from chlorine analysis, infrared spectrum analysis or in part by calculation. However, this generally has not been done. Thus, the amount of polyolefin in the grafted form was calculated in the form of a range depending on the amount of material in the hydrocarbon insoluble fraction given by the difference between Equations 3 and 4. This range is reported and used or a more specific number is used if additional data is available for a particular sample. ##EQU2##

The pellets after perchloroethylene treatment are freed of residual perchloroethylene and then extracted with dimethyl formamide (two times) by heating 1-2 hours at 100°, to give free ungrafted PVC as the soluble fraction (either discarded or may be precipitated by methanol or water if further studies are desired). The residual insoluble fraction is freed of solvent to yield polyolefin-PVC graft copolymer. For the product of Example 1 the assay numbers of interest are:

Total Polyolefin from Equation 1=23%

Range of grafted Polyolefin from Equation 3 and 4:

Equation 3: Maximum Grafted Polyolefin=23-5=18

Equation 4: Minimum Grafted Polyolefin=18-4=14 ∴Grafted Polyolefin=14 to 18%

Percent of Polyolefin Grafted (14 to 18/23) 100=61 to 78%

Polyolefin-PVC graft polymer=37%

Examples 2-10

In like manner, several other reactions were carried out following the general procedure outlined above. Only the ratio of polyolefin to vinyl chloride to free radical initiator or other parameter was changed. These are listed in Table 2. Example 2 illustrates that at a high vinyl chloride to polyolefin ratio, powder was formed in addition to the pelletized product. Most of the polyolefin remained in the pellet and very little was found in the powder. In Example 3, the weight ratio of vinyl chloride to polyolefin was 6 to 1. Some powder was also formed. In Example 4, the vinyl chloride to polyolefin ratio is 4 to 1. At this ratio only pellets were formed with no powder. Examples 5-8 illustrate lower vinyl chloride to polyolefin ratios which give compositions with higher polyolefin contents.

In Example 9, too little free radical initiator was added to convert the vinyl chloride to a high degree. The polyolefin is not as highly grafted as in Examples 1-8. However, if the recovered product from Example 9 is reacted as shown in Example 10, it is possible to restart or continue the reaction and to make highly grafted product. It is possible to further react any other product to give lower level polyolefin containing products. Reference to Example 10 means a product prepared in two (or more) steps. Reference to other Examples in Table 2 means that the general conditions of Example 1 were followed using the ratio of reactants given by the particular example in Table 2.

                                      TABLE 2                                      __________________________________________________________________________     REACTION OF VINYL CHLORIDE WITH THE POLYOLEFIN PELLETS OF EXAMPLE 1 AT         60° WITH                                                                t-BUTYLPEROXYNEODECANOATE INITIATOR, REACTOR STIRRED AT 15-20 RPM              Ex-       Vinyl     Reaction % Free                                                                               %       % Total                                                                               % Grafted                    am-                                                                               Polyolefin                                                                            Chloride                                                                            Initiator                                                                           Time Yield                                                                              Flowing                                                                              Vinyl Chloride                                                                         Polyolefin                                                                            Polyolefin                                                                            % Graft               ple                                                                               (g)    (g)  (ml) Hours                                                                               (g) Product                                                                              Conversion                                                                             In Product                                                                            In Product                                                                            Copolymer             __________________________________________________________________________     2   30    500  0.5  5    371 65 pellets                                                                           68      (8) pellet                                                                              7-9.5                                                                               14                                                 34 powder     ˜0 powder                                                                               2                    3   50    300  0.5  4    275 84 pellets                                                                           69      (18)   16-17  41                                                 10 powder                    2                    4   75    300  0.5  4    235   97  54      32     15-23  27                    5  100    300  0.5  4    275 ˜100                                                                           63      36     23-29  33                    6  110    280  0.5  4    248 ˜100                                                                           47      44     26-34  41                    7  125    330  0.5  4    276 ˜100                                                                           46      45     28-35  44                    8  150    225  0.7  4    256 ˜100                                                                           47      59     25-47  46                    9  125    250  0.3  4    157   96  13      80     10-23  29                    10 150 of like                                                                           280  0.5  4    267 ˜100                                                                           42      48     28-37  65                       product from                                                                   Example 9                                                                   __________________________________________________________________________      *In Example 2, the initiator was lauroyl peroxide and the temperature was      70° C.                                                            

Example 11

(A) In a 5 gallon stainless steel reactor equipped with a helical up-pumping agitator, was charged 4 pounds of the pelletized polyolefin described in Example 1. The vessel was pressurized with nitrogen to 180 psig and evacuated. Nine ml of the initiator of Example 1 and 12 pounds of vinyl chloride containing 5% isobutane were charged and the agitator was operated at 40 rpm and the jacket heated at 60° C. The pressure gradually increased to a maximum of 155 psig, and then fell. The reaction was allowed to proceed for 4 hours and then the unreacted monomer was recovered. Then 18 ml of a butyltin mercaptoacetate ester were added with 3 lbs. of VCM. The mixture was heated and stirred for 20 minutes. The unreacted monomer was recovered. The product was degassed under vacuum at 80° C. for 2.5 hours. The yield of white pellets was 11.5 pounds with a calculated polyolefin content of 35%. By the assay method discussed in Example 1, it was estimated that the product contained at least 21% polyolefin in the grafted form.

(B) In a still larger preparation, 2,000 lbs. of the polyolefin of Example 11(A), 6,700 lbs. vinyl chloride, and 4.7 liters of the initiator in Example 1, were charged to a reactor and heated initially at 60° followed by cooling the jacket to maintain a maximum internal pressure of 150 psig. The reaction was carried out for 2.5 hrs. followed by degassing, etc. The recovered product 6,300 lb. has a calculated polyolefin content of 31.5%. The isolated product was 99+% in the form of free flowing pellets. Only small amounts of powder (0.5%) and agglomerated pellets and scale (0.3%) were observed in the product.

Example 12--Aqueous Medium

In the reactor described in Example 1, equipped with a turbine type agitator, were charged 50 grams of the polyolefin of Example 1 and 400 ml water. The vessel was pressure tested and vented. Initiator (0.2 ml of 60 percent sec-butyl peroxydicarbonate in mineral spirits) and vinyl chloride (150 grams) were charged. The stirrer was operated at 500 rpm and the jacket was heated to 60° C. Initially the vinyl chloride floated on the water and the pellets floated on the vinyl chloride. The vinyl chloride was rapidly absorbed into the pellets and the swollen pellets floated on top of and were mixed into the moving water. The pellets quickly floated on top of the water if the stirrer was turned off. The pressure of the system increased to a maximum of 104 psig at 2 hours into the heating cycle. After 4 hours of heating, the pressure had fallen to 86 psig, and the unreacted monomer was recovered. The pellets were isolated from the water on a screen and dried to constant weight at room temperature. The yield was 129 grams of all free flowing pellets, containing 39% polyolefin and 53% vinyl chloride conversion. Assay as in Example 1 gave 28-32% grafted polyolefin and 48% graft polymer content.

Example 13

Other commercial polyolefins, available as pellet, crumb, or bale were blended with a commercial high density polyethylene by milling on a Farrell Mill (mill rolls at 350° F. for 3 minutes), followed by grinding with a Wiley Mill to pass 6 mm, and were evaluated as to suitability for this type of reaction. Vinyl chloride was the monomer in all cases, and the procedure and ratio of reactants of one of the above examples was employed as indicated in Table 3. The results of these examples are summarized in Table 3. Example 13A illustrates that when the polyolefin did not absorb monomer, then a graft polymer was not made. On the other hand, when the polyolefin is partially soluble in the monomer as in Examples 13F and 13H, mixtures tend to solidify or agglomerate into a single mass of material. On the other hand, the other polyolefins or polyolefin blends in Table 3 absorb monomer but remain insoluble so that useful compositions were prepared. Table 3 shows that many polyolefins can be converted to a form suitable to this type of reaction. Also it is noted that polymers other than high density polyethylene can be used to convert a polyolefin to a form suitable for reaction. Any other composition or mixture that meets the criteria of absorbing monomer but not dissolving in the monomer (or at least not dissolving during the time of reaction) will work and is considered to be within the spirit and intent of this disclosure.

Example 14

Any monomer-polymer combination that meets the criteria that the monomer will be absorbed into the polymer without dissolving the polymer can be used in the process of the invention. Thus, for instance, reactions of Table 4 illustrate the reaction of the polyolefin of Example 1 with other monomers.

                                      TABLE 3                                      __________________________________________________________________________     Example 13                                                                                              Reaction                                                                       Condition                                                                      For                                                   Polyolefin Composition   Evaluation                                                                           Result                                          __________________________________________________________________________     A.                                                                               High density polyethylene (HDPE) pellets                                                              Example 5                                                                            Pellets did not absorb the monomer and                                         initiator - no                                    (control example)            reaction in the pellet - recovered                                             unreacted pellets and                                                          PVC homopolymer.                                B.                                                                               EPDM of Example 1 to HDPE ratio 15:85                                                                 Example 6                                                                            63% free flowing polyolefin products, 10%                                      powder and 27%                                                                 agglomerated product, free flowing product                                     at least 80% grafted.                           C.                                                                               EPDM of Example 1 with HDPE ratio 1:2                                                                 Example 6                                                                            88% free flowing polyolefin product at                                         least 60% grafted.                              D.                                                                               EPDM of Example 1 with HDPE ratio 2:1                                                                 Example 5                                                                            Preparation of at least 40% grafted                                            pelletized product.                                                      and 6                                                 E.                                                                               Polyolefin of Example 1 - Ratio 85:15                                                                 Example 5                                                                            Preparation of highly grafted pelletized                                       product.                                          (for comparative purposes)                                                                            and 12                                                F.                                                                               EDPM of Example 1 to HDPE 9:1                                                                         Example 12                                                                           Polyolefin mixture partially soluble in                                        monomer resulting                                                              in polyolefin agglomerating into a solid                                       mass.                                           G.                                                                               Blend of 9 parts of a pelletized EPDM of                                                              Example 12                                                                           Preparation of at least 60% grafted                                            free-flowing solid                                approximate molar ratio 75% ethylene, 25                                                                    product.                                          % propylene and 4 db/1,000 C--C unsaturation                                   as 1,4-hexadiene weight average MW 180,000                                     with 1 part HDPE                                                             H.                                                                               The EPDM of Example 13G as a pellet                                                                   Example 1                                                                            Agglomerated into a solid mass.                   without the HDPE                                                             I.                                                                               A 9:1 blend of a crumb EPDM of                                                                        Example 12                                                                           Preparation of at least 70% grafted free                                       flowing solid                                     approximate molar ratio of 80% ethylene, 20                                                                 product.                                          propylene and 5 db/1,000 C--C unsaturation                                                            Example 6                                                                            95% free flowing product, some of it                                           agglomerated into                                 as ethylidene norbornene of weight average                                                                  larger particles.                                 molecular weight of about 220,000 with                                         HDPE.                                                                        J.                                                                               A 85%-15% blend of a bale EPDM of                                                                     Example 12                                                                           Preparation of at least 80% grafted                                            free-flowing solid                                approximate molar ratio 65% ethyelene, 35%                                                                  product.                                          propylene, 4 db/1,000 C--C unsaturation as                                     ethylidene norbornene having weight                                            average molecular weight of about 200,000                                      with HDPE.                                                                   K.                                                                               A pelletized EPR having about 80 mole                                                                 Example 5                                                                            85% free flowing product with 15%                                              agglomerated material.                            % ethylene and 20% propylene with MW                                                                        Pelletized material was at least 70                                            percent grafted.                                  of about 400,000.                                                            L.                                                                               Polyolefin similar to that in 13K                                                                     Example 12                                                                           85% free flowing product.                         except ground through 5 mm.                                                  M.                                                                               Polyolefin of 13L with 5% HDPE.                                                                       Example 12                                                                           96% free flowing product, 95% grafted.          O.                                                                               A commercial pelletized ethylene-                                                                     Example 12                                                                           96% free flowing highly grafted pelletized                                     product.                                          vinyl acetate copolymer having 9%                                                                           Starting pellets floated on water, product                                     pellets sank.                                     vinyl acetate.         Example 5                                                                            75% pellets, 6% powder, 19% agglomerated                                       pellets in the                                                                 bottom of the reactor.                          P.                                                                               80% of a bale EPDM with 65 molar ratio %                                                              Example 5                                                                            50% free flowing product, rest stuck on                                        the wall of                                       ethylene, 35% propylene, 10 db/1,000 C--C                                                                   the reactor. Conversion of vinyl chloride                                      was low.                                          unsaturation as ethylidene norbornene                                          of about 180,000 weight average                                                molecular weight with 20% HDPE.                                              Q.                                                                               Commercial polypropylene                                                                              Example 6                                                                            Pellets do not absorb monomer. Product is                                      unreacted                                                                      pellets plus powder.                            R.                                                                               EPDM of Example 1 with polypropylene                                                                  Example 12                                                                           Polyolefin blend dissolved in the                                              monomer.                                          ratio 85:15.                                                                 S.                                                                               A pelletized 45% vinyl acetate - 55%                                                                  Example 12                                                                           50% as agglomerated balls of various                                           sizes, rest a                                     ethylene copolymer with HDPE 3:1                                                                            coating on the reactor wall.                    T.                                                                               A bale EPDM of molar ratio 65% ethylene,                                                              Example 12                                                                           Agglomerated with monomer.                        35% propylene, 5 db/1,000 C--C unsaturation                                    as ethylidene norbornene of about 160,000                                      weight average molecular weight blended                                        4:1 with HDPE                                                                U.                                                                               The EPDM of T with HDPE 3:1                                                                           Example 12                                                                           Agglomerated with monomer.                      V.                                                                               The EPDM of Example 1 blended with high                                                               Example 12                                                                           Good particle distribution, but low                                            conversion.                                       molecular weight polystyrene 85:15                                           W.                                                                               The EPDM of A blended with a thermo-                                                                  Example 12                                                                           Agglomerated with monomer.                        plastic elastomer containing                                                   tetramethylene terephthalate and                                               tetramethylene ether components.                                             X.                                                                               The EPDM of G with polymethylmeth-                                                                    Example 12                                                                           95% free flowing particles.                       acrylate at a ratio of 9:1.                                                  Y.                                                                               The EPDM of G with the product of                                                                     Example 12                                                                           87% free flowing product.                         Example 15A in the ratio of 9:1.                                             Z.                                                                               The pellets as in Example 1 blend from                                                                Example 4                                                                            92% pellets                                       whence the EPDM was extracted (ie porous                                                                    8% powder                                         polyethylene pellets)                                                        __________________________________________________________________________

                                      TABLE 4                                      __________________________________________________________________________     Example 14                                                                     __________________________________________________________________________     Reaction of 10 g polyolefin of Example 1 with Monomers and 0.1 ml of the       initiator of Example 1 for 2 hours at 65° with shaking in a 4 oz.       bottle.                                                                                                          Yield (Grams) After                                                            Shaking With                                 Reaction                                                                            Monomer    Amount                                                                              Appearance After Shaking                                                                    Isopropyl Alcohol                                                                        Product - Notes                    __________________________________________________________________________     A    Styrene    5 ml Free-flowing clear                                                                           9.9      Similar to starting                                     pellets                pellets                            B    Methyl Methacrylate                                                                       5 ml Loosely agglomerated wet                                                                     9.8      Has white spots                                         pellets                                                   C    Styrene    2.5 ml                                                                              Loosely agglomerated                                                                        10.1      Like starting material                  Methyl Methacrylate                                                                       2.5 ml                                                         D    Butyl Maleate                                                                             2.5 ml                                                                              Free-flowing with liquid                                                                    11.0      Like starting material                  Styrene    2.5 ml                                                         E    Methyl Acrylate                                                                           5 ml Wet looking some                                                                            11.9                                                              agglomeration                                             F    Maleic Anhydride                                                                          2.5 g                                                                               White free flowing                                                                          14.6      Opaque                                  Styrene    2.5 ml                                                         G    Methyl Methacrylate                                                                       10 ml                                                                               Clear-ball like                                                                             17.5      Nearly clear colorless                                                         pellets. Bigger than                                                           starting material                  H    Styrene    10 ml                                                                               White-free flowing                                                                          16.5      White pellets. Bigger                                   Pellets                than starting                      __________________________________________________________________________                                                 material.                          Reaction of 10 g of the polyolefin of Example 1 with monomers and 0.25 ml      of the                                                                         initiator of Example 1 with shaking for 4 hours at 65° then             static at 65° for an additional 16 hrs. in 4 oz. bottles.                                                        Yield (Grams) After                                     Amount                 Extraction With                       Reaction                                                                              Monomer    Ml       Appearance After Reaction                                                                    Isopropyl Alcohol                     __________________________________________________________________________     A      Styrene    5        free flowing pellets                                                                         14.7                                  B      Methylmethacrylate                                                                        5        free flowing pellets                                                                         14.9                                  C      Methylmethacrylate                                                                        2.5      free flowing pellets                                                                         12.5                                  D      Styrene    2.5      free flowing pellets                                                                         12.2                                  E      Styrene    2.5      free flowing pellets                                                                         14.5                                         Methylmethacrylate                                                                        2.5                                                          F      Styrene    1        free flowing pellets                                                                         12.1                                         Methylmethacrylate                                                                        1                                                            G      Styrene     3.75    free flowing pellets                                                                         14.7                                         Acrylonitrile                                                                              1.25                                                        H      Styrene    2.5      some sticking to the                                                                         13.9                                         Butyl Maleate                                                                             2.5      bottle                                              I      Cyclohexyl Acrylate                                                                       2.5      some sticking to the                                                                         12.1                                                             bottle                                              J      Methyl Acrylate                                                                           2.5      some sticking to the                                                                         12.5                                                             bottle                                              K      Methyl Acrylate                                                                           2.5      some sticking to the                                                                         14.8                                         Styrene    2.5      bottle                                              L      Lauryl Methacrylate                                                                       2.5      some sticking to the                                                                         12.1                                                             bottle                                              __________________________________________________________________________

In Example 14, the monomers were largely absorbed into the pellets without dissolving them. After the reactions, the products were shaken with isopropyl alcohol to wash out any residual monomer. The products in Reactions D to H of Table 4, Part 1 weigh more than the starting polyolefin indicating that polymerization has taken place. It is important to note that the polyolefin did not dissolve together or fuse solidly into a mass. In a second series, in Example 14 (Table 4 - part 2) more initiator and longer reaction times were used to give products with almost all of the monomer converted to polymer. The pellets remained free flowing or in some cases some sticking was observed and the monomers polymerized in the pelletized polyolefin.

Example 15A

In another reaction of the same reactants as in Reaction B of Example 14 (Table 4, part 1) and in Reaction B of Example 14 (Table 4, part 2), using the same reactor as described in Example 1, where 100 g of the polyolefin, 50 ml of methylmethacrylate and 1 ml of the t-butylperoxyneodecanate were heated with stirring for 6 hours, a yield of 134 g of freeflowing clear pellet product was obtained indicating 85% conversion of the methyl methacrylate to polymer. An extraction of a sample at 65° by shaking with dimethyl formamide, a solvent for polymethylmethacrylate homopolymer dissolved 21% of the material indicated that 25% of the polymethyl methacrylate is actually grafted to the polyolefin in the pellets.

Example 15B

The product of Example 15A can be used directly or may be reacted in subsequent steps with other monomers to make different products. Thus, for instance, 50 g of the product of Example 15A along with 0.3 ml of the same initiator and 170 g of vinyl chloride were reacted in the same reactor at 60° for 4 hours. After recovery of unreacted vinyl chloride, a yield of 177 g of free flowing pelletized product was realized.

Example 15C

Stepwise reactions with two monomers can be carried out in the reverse order. Thus, a product was made according to Example 5 and then at the end of reaction and degassing 0.5 ml of the same initiator and 25 ml methyl methacrylate were charged and the mixture heated for 2 hours at 65° followed by final degassing to yield 312 g of pelletized product.

Example 16

The principle of the reaction is not limited to the polyolefins illustrated above. A blend of 2 parts of a commercial solution prepared polybutadiene of weight average molecular weight of 225,000 was blended with 1 part of HDPE on a mill at 340°-350° F. and ground to pass a 5 mm screen. This material was reacted with other monomers according to Table 5.

                                      TABLE 5                                      __________________________________________________________________________     Example 16                                                                     Reaction of 10 g Polybutadiene-Polyethylene Blend with 0.1 ml of t-butyl       Peroxyneodecanoate                                                             and Monomer with Shaking at 65° for 19 Hours                                                        Soluble In                                                                              Soluble                                                                             Yield After                                                      Isopropyl Alcohol                                                                       Acetone                                                                             Extraction                           Run                                                                               Monomer    ml                                                                               Product After Shaking                                                                      (g)      (g)  (g)                                  __________________________________________________________________________     A  Styrene    5 Small ball, some stuck                                                                     0.1      0.3  13.6                                                 to wall, rest free-flowing                                     B  Styrene    2.5                                                                              Free-flowing                                                                               0.1      0.6  14.8                                    Metyl Methacrylate                                                                        2.5                                                              C  Styrene    3.5                                                                              Free-flowing                                                                               0        0.2  14.4                                    Acrylonitrile                                                                             1.5                                                              D  Methyl Methacrylate                                                                       5 Free-flowing, some                                                                         0.1      0.9  13.8                                                 stuck to wall                                                  E  Styrene    7.5                                                                              Loosely agglomerated                                                                       0        0.4  19.4                                    Acrylonitrile                                                                             2.5                                                                              ball                                                           F  Styrene    10                                                                               Some stuck to wall,                                                                        0.1      0    18.7                                                 rest free-flow                                                 __________________________________________________________________________

For all combinations in Example 16, the monomers were almost totally converted to polymers judged by isopropyl alcohol extraction (shaken 1 hour, 65°, decant and dry) for monomers. After freeing the samples of residual isopropyl alcohol, they were extracted with acetone by shaking in a bottle in a bath at 65°. Acetone dissolves part or all of the homopolymers or copolymers involved here. Thus, the illustrated monomers are to a large degree grafted to the polyolefin. These materials themselves may be formed into useful articles or they may be used as impact modifiers for PVC, polystyrene, styrene-acrylonitrile, polymethylmethacrylate or many other polymeric materials to make useful products.

Examples 17 to 21

The reaction of other polyolefins or other related materials is illustrated by Examples 17, 18, 19, 20 and 21. The starting polyolefin or other insoluble polymer capable of absorbing monomer were either of commercial nature or prepared according to Example 13. Reactions were generally carried out as in Example 16 where the solid, initiator and monomers were mixed in a 4 oz. bottle and shaken in a constant temperature bath at 65° for a time and the residual unreacted monomer was washed out of the polymer using isopropyl alcohol and the product dried to constant weight. In Example 17 a commercial pelletized ethylene vinyl acetate having 9% vinyl acetate was used to make products having essentially all of the starting monomer bound in the pellets which were free flowing.

In Example 18, a commercial pelletized star block copolymer having blocks of polybutadiene (70%) and polystyrene (30%) was reacted with a similar series of monomers. It is noted here that the monomers tend to stick the pellets together although the mixture did not solidify into a solid mass. The yield of polymer in Examples 18 A-D was in the low to medium range. However, if some isopropyl alcohol, an inert diluent, is added and the reaction time extended, the yield of product and the particle distribution are both improved.

In Example 19 several monomers were reacted with a solution prepared polybutadiene blended 3:1 with HDPE for 4 hours. The monomers were absorbed into the particles keeping the polyolefin a free flowing material but the conversion of monomer to polymer was slight. The recovered polyolefin blends from several of these examples were reused in the experiments in Example 20. Here the initiator level and the reaction time were both increased to yield several free flowing graft copolymer compositions. In examples with styrene and styrene maleic anhydride, reclaimed polyolefin blend now gave high yield polymer. The reactions with vinyl acetate and butyl vinyl ether still showed little conversion under these conditions. Copolymers with styrene-acrylonitrile and styrene-methyl methacrylate on new unreacted blend were also prepared in good yield.

In Example 21,--a star block copolymer similar to that used in Example 18, but having a butadiene ratio to styrene ratio of 60:40 was used. This material was more prone to dissolving in the monomers used to the extent that blending with polyethylene and adding isopropyl alcohol only gave marginal results. The star block copolymer in E and F totally dissolved into the monomers. The reacions E and F in Example 21 would have little chance of success in the process at hand owing to too great a solubility while most of those other reactions in Examples 21 and 17 to 20 illustrate the point of the monomer going into the solid phase and polymerizing without dissolving the polyolefin or other solid material.

                                      TABLE 6                                      __________________________________________________________________________     Example 17                                                                     Reaction of an ethylene-vinyl acetate copolymer containing 9% vinyl            acetate with some monomers and 0.15ml                                          di-sec-butyl peroxydicarbonate in 60% mineral spirits at 65° in a       Shaker bath for 6 hrs.                                                                                           After Reaction,                                   Wt.              Appearance After                                                                           Weight Extracted by                                                                       Yield of                          Reaction                                                                            EVA.                                                                               Monomer   ml Shaking     Isopropyl Alcohol                                                                         Polymer                           __________________________________________________________________________     A    10.6                                                                               Styrene   5  free-flowing pellets                                                                       0.3        15.1                              B    10.0                                                                               Styrene   2.5                                                                               lightly stuck together                                                                     0.3        14.7                                       methyl methacrylate                                                                      2.5                                                                               into a ball which easily                                                       broke apart                                              C    10.2                                                                               methyl methacrylate                                                                      5  as in B     0          15.0                              D    10.2                                                                               Styrene   3.75                                                                              as in B     0.3        14.7                                       Acrylonitrile                                                                            1.25                                                        __________________________________________________________________________

                                      TABLE 7                                      __________________________________________________________________________     Example 18                                                                     Reaction of a commercial pelletized star block copolymer containing 70%        polybutadiene and 30% styrene                                                  with monomers and 0.15 ml of di-sec-butyl peroxydicarbonate in 60%             mineral spirits at 65° in a Shaker bath.                                                         Reaction                                                   Wt.                 Time Appearance After                                                                          Yield after Isopropyl                 Reaction                                                                            Star S--BR                                                                           Monomer    ml hr.  Reaction   Alcohol Extraction                    __________________________________________________________________________     A    10.1  Styrene    5  6    mostly stuck together                                                                     10.1                                                                to the walls but still                                                         pellets (not fused                                                             into a single mass)                              B    9.9   Styrene    2.5                                                                               6    as in A    11.5                                             Methyl Methacrylate                                                                       2.5                                                      C    9.7   Methyl Methacrylate                                                                       5  6    mostly as in A - some                                                                     9.6                                                                 pellets free                                     D    9.9   Styrene    3.75                                                                              6    as in A    13.3                                             Acrylonitrile                                                                             1.25                                                     E    10.0  Styrene    2.5                                                                               6 shaken                                                                            free flows 17.1                                             Methyl Methacrylate                                                                       2.5                                                                               +    lightly stuck together                                      Isopropyl Alcohol                                                                         5  16 static                                                                           and to wall                                      F    10.4  Styrene    3.75                                                                              6 shaken                                                                            free flowing pellets                                                                      14.7                                             Acrylonitrile                                                                             1.25                                                                              16 static                                                        Isopropyl Alcohol                                                   __________________________________________________________________________

                                      TABLE 8                                      __________________________________________________________________________     Example 19                                                                     Reaction of a 3:1 polybutadiene-HDPE blend with monomers using 0.1 ml          di-sec-butyl peroxydicarbonate                                                 with shaking at 65° for 4 hours.                                             Wt. Poly-           Appearance   Yield After Isopropyl                    Reaction                                                                            olefin Blend                                                                          Monomer    ml                                                                               After Reaction                                                                              Alcohol Extraction                       __________________________________________________________________________     A    10.1   Styrene    5 loosely agglomerated                                                                        10.5                                                              no liquid                                             B    9.9    Methyl Methacrylate                                                                       5 free flowing 10.4                                                              no liquid                                             C    9.7    Methyl Acrylate                                                                           5 free flowing not determined no liquid                 D    10.3   Vinyl Acetate                                                                             5 free flowing 10.2                                                              no liquid                                             E    9.9    Acrylonitrile                                                                             5 particulate like but all                                                                    12.7                                                              stuck to the wall                                     F    9.9    Vinyl Bromide                                                                             5 free flowing  9.9                                                              no liquid                                             G    10.1   Styrene    2.5                                                                              free flowing 12.5                                                 Maleic Anhydride                                                                          2.5                                                                              brown spots, some maleic                                                       anhydride solid                                       H    10.2   Butyl Vinyl Ether                                                                         5 free flowing 10.4                                                              no liquid                                             __________________________________________________________________________

                                      TABLE 9                                      __________________________________________________________________________     Example 20                                                                     Reaction of a 3:1 polybutadiene-HDPE blend with monomers using 0.15 ml         di-sec-butyl peroxydicarbonate 60% in                                          mineral spirits in a bath at 65° with shaking for 6 hours and           static fo another 16 hours.                                                         Wt. Poly-                     Appearance  Yield After                     Reaction                                                                            olefin Blend                                                                          Source of Blend                                                                         Monomer    ml After Reaction                                                                             Monomer Removal                 __________________________________________________________________________     A    10.2   New      Styrene    3.75                                                                              Free flow to loosely                                                                       14.6                                                 Acrylonitrile                                                                             1.25                                                                              agglomerated                                B    10.0   New      Styrene    2.5                                                                               Same as A   14.8                                                 Methyl Methacrylate                                                                       2.5                                            C    11.9   Recovered 19 - G                                                                        Styrene    2.5                                                                               Free flowing with some                                                                     17.0                                                 Maleic Anhydride                                                                          2.5                                                                               on the wall                                 D    8.8    Recovered 19 - A                                                                        Styrene    5  Free flowing                                                                               13.4                            E    8.6    Recovered 19 - B                                                                        Methyl Methacrylate                                                                       5  Free flowing at start                                                                      --                                                                 Sample lost                                 F    9.6    Recovered 19 - D                                                                        Vinyl Acetate                                                                             5  Free flowing                                                                               10.1                            G    10.0   Recovered 19 - H                                                                        Butyl Vinyl Ether                                                                         5  Free flowing to slightly                                                                   10.2                                                               agglomerated                                __________________________________________________________________________

                                      TABLE 10                                     __________________________________________________________________________     Example 21                                                                     Reaction of a commercial pelletized star block copolymer containing            60% polybutadiene and 40% polystyrene also                                     blends of the same polymer blend with high density polyethylene                at 3:1 using 0.1 ml di-sec-butyl peroxydicarbonate,                            60% mineral spirits and 5 ml isopropyl alcohol at 65° with              shaking.                                                                            Polyolefin               Appearance Yield After Extracting                Reaction                                                                            Nature -                                                                               Wt.                                                                               Monomer    ml After 2.5 hr. Reaction                                                                    Unreacted Monomer                     __________________________________________________________________________     A    HDPE Blend -                                                                           10.5                                                                              Styrene    5  loose ball 11.6                                  B    HDPE Blend -                                                                           9.7                                                                               Styrene    2.5                                                                               loose ball 11.7                                                  Methyl Methacrylate                                                                       2.5                                                 C    HDPE Blend -                                                                           9.9                                                                               Methyl Methacrylate                                                                       5  some free flow, some                                                                      14.5                                                                agglomerated                                     D    HDPE Blend -                                                                           9.9                                                                               Styrene    3.75                                                                              loosely on the wall                                                                       12.3                                                  Acrylonitrile                                                                             1.25                                                E    Star Polymer -                                                                         9.9                                                                               Styrene    5  dissolved  11.0                                  F    Star Polymer -                                                                         10.4                                                                              Methyl Methacrylate                                                                       5  dissolved  12.7                                  __________________________________________________________________________

Example 22

Some reagents were screened as to their suitability in stabilizing typical compositions by shaking 10 grams of pellets made in accordance with the reactants and procedure of Example 10, but having 30% total polyolefin with 2.5 ml hexane as the carrier media and a stabilizer in a bottle in a bath at 65° for one hour, evaporating the carrier and then heating in an oven for a period of time and comparing the color of the resulting materials. Results are given in Table 11. Of those listed, the butyltin mercaptoacetate ester, the nonylphenyl phosphite and the alkyltin maleate are most effective in keeping the color of the pellets to a minimum. The latter material, a solid, seems to be surprisingly more effective when used with ethanol as a solvent than it is when either alone or with other solvents.

Example 23

(A) In a reaction process of the invention, the stabilizer is flushed into the reactor with vinyl chloride monomer after the end of the reaction time. The reactor may be cooled or some vinyl chloride monomer can be vented from the reactor to recovery to facilitate this addition. The vinyl chloride can be heated or pumped to drive it into the reactor. The mixture is then heated and stirred for a short time, e.g. 15 minutes, to drive the stabilizer into the particles and then the monomer is recovered normally. Examples in Table 12 prepared using the polyolefin of Example 1 and employing synthesis procedures of Examples 5-8 illustrate this stabilization procedure. After the main bulk of the monomer was recovered, the pellets were heated under vacuum to bring the residual volatiles levels, as determined by allowing the final product, to stand in a hood with a good draft 20 hours, to low or indicated levels.

                                      TABLE 11                                     __________________________________________________________________________     Example 22                                                                                             Result After Heating At 100°                    Stabilizer         Amount                                                                              2-4 Hours                                                                             20 Hours                                        __________________________________________________________________________     A None - Control        Light Purple                                                                          Purple                                          B Butyltin Mercaptoacetate Ester                                                                  0.05 ml                                                                             White  White to Light Pink                             C Nonylphenyl Phosphite                                                                           0.25 ml                                                                             White  Light Brown                                     D Dibutyl Maleate  0.5 ml                                                                              Light Purple                                                                          Same                                            E Epoxyidized Soya 0.1 ml                                                                              Light Purple                                                                          Purple                                          F 20% Solution of an Alkyl                                                                        0.1 ml                                                                              White  White to Light Pink                               Tin Maleate in Ethanol                                                       G 20% Solution of Alkyl Tin                                                                       0.25 Pink   Light Purple                                      Maleate in Toluene                                                           H 20% Solution of an Alkyl                                                                        0.25 Light Pink                                                                            Light Purple                                      Tin Maleate in Perchloroethylene                                             I 20% Solution, 2,6-dibutyl                                                                       0.4 ml                                                                              Light Purple                                                                          Purple                                            p-cresol in ethanol                                                          __________________________________________________________________________

                                      TABLE 12                                     __________________________________________________________________________     Example 23                                                                                           Heating Under Vacuum                                                           Time                                                                              Temp.                                                 Run                                                                               Stabilizer phr on Pellets                                                                         Hr.                                                                               ° C.                                                                        Color Volatiles (percent)                         __________________________________________________________________________     A  None - Control     2  80  Purple                                                                               0.16                                        B  Dibutyltin 0.1     2.5                                                                               90  Light Pink-                                                                          0                                              Mercaptoacetate Ester     Purple                                            C  Dibutyltin 0.4     2.5                                                                               90  White 0.45                                           Mercaptoacetate Ester                                                       D  Nonylphenyl                                                                               0.4     2.5                                                                               80  White 0.13                                           Phosphite                                                                   E  Nonylphenyl                                                                               0.2     2.5                                                                               95  Light Pink                                                                           0.1                                            Phosphite                                                                   F  Commercial Alkyltin                                                                       0.1     3  90  Off White                                                                            0                                              Maleate 20% in                                                                            (0.5 of solution)                                                   Ethanol                                                                     G  Commercial Alkyltin                                                                       0.1     3  95  Off White                                                                            0                                              Maleate and Ethanol                                                                       0.3                                                                 added at start of                                                              reaction                                                                    __________________________________________________________________________

Example 23 illustrates how the three materials allowed the resin to be heated hotter and longer than the control while still keeping the color of the pellets light or white. Additionally in Example 23G, the combination of alkyltin maleate in ethanol was added at the start of the reaction with no effect on the reaction. This allowed the end of reaction addition step to be avoided and still giving good color retention during the degassing.

(B) The color in products such as Example 23A can be reacted out. Thus, 10 g of product like 23A was treated with 1 ml methylmethacrylate and 0.05 ml 60% di-sec-butyl peroxydicarbonate in mineral spirits with shaking at 65° for 1 hr. At the end of this time most of the pellets were colorless although there were traces of color at the center of some pellets which gradually faded as the reactants slowly reached the center. Similar results were obtained using 0.5 ml styrene in place of the methylmethacrylate. If only 0.05 ml methylmethacrylate were used with 0.005 ml initiator, very little reaction took place. However, the same charge including 1 ml of a hydrocarbon solvent was as effective as the first mentioned reaction in removing the color.

Example 24--Transparent Graft Polymer

Reactions were carried out in accordance with Example 2. Pellets as described in Example 1, initiator, and monomer were added to a reactor and heated with stirring at 60° to make product. In Example 24C, product from one reactor was added back to the reactor with more monomer and initiator and the process repeated. In Example 24B, after initial reaction the reactor was cooled to charge more initiator and monomer and then heated to continue the reaction. Examples in Table 13 illustrate the synthetic scheme.

                                      TABLE 13                                     __________________________________________________________________________     Example 24                                                                                        Reaction            Percent                                                                              Percent                                Polyolefin                                                                           VCM  Init.                                                                             Time Yield                                                                               %    VCM  Total Graft                             Ex. No.                                                                             (grams)                                                                              (grams)                                                                             ml (hours)                                                                             (grams)                                                                             Pellet                                                                              Conv. %                                                                             Polyolefin                                                                           Polyolefin                        __________________________________________________________________________     A    30    500  0.5                                                                               5    371  65   68   8.1   14                                                             34                                                                             Powder                                            B    75    280  0.5                                                                               2.5  403  97   71   18.5  51                                     at 2.5 hr.                                                                           180  0.5                                                                               +2                                                          C-1  1800  3650 6  5    3850 100  56   47    44                                C-2  200 of C-1                                                                           660  1  4    570  89   56   18    32                                     product                 11                                                                             Powder                                            C-3  150 of C-2                                                                           280  0.5                                                                               3    351  88   70   9     38                                     product                  7                                                                             Powder                                            __________________________________________________________________________

In the control Example 24A, a product with 8.1% total polyolefin was made of which 65% was pellets and 34% powder. In Example 24B a product with 18% total polyolefin was prepared and only 3% was powder. One more monomer addition step would be required to bring this into the same range as the control.

In Example 24C, a product having 9% total polyolefin was prepared with minimal powder in two of the three steps and none in the other. A 115 gram sample of the pellets was worked on a mill at 350° F. with 2 grams of dibutyltin mercaptoacetate ester stabilizer and 2 grams of acrylate process aid for 5 minutes, sheeted out and compression molded at 350° F. and 1000 psi into a 6×6" plaque 1/8" thick. This plaque when placed on a printed page had sufficient clarity to read the printing through it vs a plaque from the control which was too opaque to read through. The sample was cut into samples for testing. These had 13.1 ft.-lb./in. impact in the notched Izod test vs. 19.8 ft.-lb./in. for the control. Both failed in a ductile fashion with crease whitening.

Example 25--Co-Manufacture of PVC and Graft Polymer by Mass Polymerization

A 21/2 gallon reactor equipped with a turbine type agitator was charged with 0.7 ml of a 75% solution of sec-butyl peroxydicarbonate and 16 lb. vinyl chloride. The agitator was operated at 1200 rpm during the reaction time which consisted of 18 minutes heating to 170 psig and 35 minutes at this pressure to a low degree of conversion of vinyl chloride. The resulting mass was transferred to a 5 gallon reactor equipped with a helical stirrer set for 60 rpm and containing 90 grams of the polyolefin of Example 1, 1.8 ml of a 75% solution of sec-butyl peroxy dicarbonate, 5.0 g of decanoyl peroxide and 4 lb. vinyl chloride. The resulting mass was heated until the pressure in the vessel reached 170 psig and the jacket was maintained to hold this pressure for 3.75 hr. At the end of this time the unreacted monomer was recovered and the reactor emptied. The product was screened yielding 13.4 lb. through 40 mesh (75%) powdery resin, 1 lb. (6%) of larger particle size powder that passed a 10 mesh screen but not 40 mesh, 2.1 lb. (12%) of an on 10 mesh fraction of which 1.9 lb. were in the form of pellets and 0.2 lb. agglomerated powder and scaley material, and finally 0.8 lb. (15%) of reactor scrapings, etc. The powdery fraction was essentially free of polyolefin as judged by the fact that a film pressed from it at 180° C. was clear. Also shaking a 10 g sample with 200 ml dimethylformamide (a solvent for PVC but not polyolefin) was clear indicating that the PVC powder contains little or no polyolefin. Assuming that all of the polyolefin has remained in the pellets, then the pelletized product must contain (90÷870)×100=10.4% polyolefin and 89.6% PVC. Using the method of Example 1 the pelletized product was found to contain 17% graft copolymer with 8.4-9.4% grafted polyolefin in the product. When this pelletized material was converted to a plaque according to Example 24C, the product was found to have a notched Izod impact of 19.8 ft.-lb./in.

Example 26--Co-Manufacture of PVC and Graft Polymer by Aqueous Process

Graft polymer and PVC are co-manufactured in aqueous medium by first introducing water and suspending agent into a reactor, followed by the polyolefin of Example 1, the initiator of Example 25, and vinyl chloride. The mixture is agitated and the reaction temperature is raised to 70° C. for ten hours. The resulting product comprises 15 percent of pellets of graft polyolefin and the remainder PVC powder. 

We claim:
 1. A process for concurrently producing a polyolefin graft copolymer and a homopolymer or copolymer, which comprises:(1) mixing a monomer comprising an ethylenically unsaturated polymerizable monomer in the liquid state, with a solid polymer of an aliphatic hydrocarbon monolefin of 2 to about 8 carbon atoms, wherein the olefin polymer is substantially insoluble in the monomer, but absorbs a substantial amount of the monomer, and wherein the proportion of olefin polymer is in the range of about 0.1 to about 5 percent by weight based on the weight of ethylenically unsaturated monomer, and an initiator, and (2) heating the resulting mixture at an elevated temperature to polymerize the components to produce a mixture of solid discrete particles of the polyolefin graft copolymer and finely divided powder of the homopolymer or copolymer.
 2. The process of claim 1 wherein the product of step 2 mechanically separated into the graft copolymer product and the homopolymer or copolymer product.
 3. A process for concurrently producing a vinyl halide polyolefin graft copolymer and a vinyl halide polymer or copolymer, which comprises:(1) mixing a monomer comprising vinyl halide along or in combination with up to 50 percent by weight based on the total weight of monomer of an ethylenically unsaturated monomer copolymerizable therewith, in the liquid state, with a solid polyolefin comprising a polymer of an aliphatic hydrocarbon monolefin of 2 to about 8 carbon atoms, wherein the polyolefin is substantially insoluble in the monomer or monomers, but absorbs a substantial amount of the monomer or monomers, and wherein the proportion of polyolefin is in the range of about 0.1 to about 5 percent by weight based on the weight of vinyl halide, and an initiator for the process, and (2) heating the resulting mixture at a temperature in the range of about 30 to about 90 degrees Celsius to polymerize the components to produce a mixture of solid discrete particles of the vinyl halide polyolefin graft copolymer and finely divided powder of the vinyl halide polymer or copolymer.
 4. The process of claim 3 wherein the product of step 2 is mechanically separated into the graft copolymer product and the vinyl halide polymer or copolymer product.
 5. The process of claim 3 wherein the vinyl halide is vinyl chloride.
 6. The process of claim 5 wherein the polyolefin comprises an ethylene propylene polyene terpolymer.
 7. The process of claim 6 wherein the polyolefin is a mixture of ethylene propylene polyene terpolymer and high density polyethylene. 